Three-dimensional (3D) printing

Patent metadata

Field	Value
Publication number	US-10661503-B2
Application number	US-201616064098-A
Country	US
Kind code	B2
Filing date	Apr 13, 2016
Priority date	Apr 13, 2016
Publication date	May 26, 2020
Grant date	May 26, 2020

Abstract

In a three-dimensional (3D) printing method example, build material granules are applied. Each of the build material granules includes a plurality of primary ceramic particles agglomerated together by a binder that is at least partially soluble in a primary solvent of a fusing agent. Pressure is applied to crush the build material granules. The fusing agent is selectively applied on at least a portion of the build material granules or the crushed build material granules to pattern the portion, and to introduce a latent binder to the portion. The application of the build material granules, the application of the pressure, and the selectively application of the fusing agent are repeated to create a green body. The latent binder is activated by heating the green body in order to produce a cured green body.

First claim

What is claimed is:

1. A three-dimensional (3D) printing method, comprising:
applying build material granules, each of the build material granules including a plurality of primary ceramic particles agglomerated together by a binder that is at least partially soluble in a primary solvent of a fusing agent;
applying pressure to the build material granules, thereby crushing the build material granules;
selectively applying the fusing agent on at least a portion of the build material granules or the crushed build material granules, thereby patterning the build material granules or the at least the portion of the crushed build material granules, and introducing a latent binder to the at least the portion of the build material granules or the crushed build material granules;
repeating the applying of the build material granules, the applying of the pressure, and the selectively applying of the fusing agent to create a green body; and
activating the latent binder by heating the green body, thereby producing a cured green body.

2. The 3D printing method as defined in claim 1 , further comprising:
exposing the cured green body to a wet extraction process, thereby removing any non-bound crushed build material granules;
heating the cured green body, thereby thermally decomposing the latent binder to form a densified green body; and
sintering the densified green body to form a 3D object.

3. The 3D printing method as defined in claim 2 wherein the wet extraction process includes:
sonicating the cured green body in water; or
spraying the cured green body with water and washing away the non-bound crushed build material granules from a surface of the cured green body.

4. The 3D printing method as defined in claim 2 wherein the heating of the cured green body takes place at a first temperature, and wherein the sintering of the densified green body takes place at a second temperature that is higher than the first temperature.

5. The 3D printing method as defined in claim 4 wherein the first temperature ranges from about 250° C. to about 600° C., and wherein the second temperature is at least 900° C.

6. The 3D printing method as defined in claim 1 wherein the latent binder is a polymer particle dispersion.

7. The 3D printing method as defined in claim 6 wherein:
the polymer particle dispersion includes core-shell polymer particles, each of the core-shell polymer particles having a hydrophobic polymer core and a hydrophilic polymer shell; and
the activating of the latent binder is accomplished by exposing the green body to a temperature above a film forming temperature of the hydrophobic polymer core and below a threshold temperature at which thermal decomposition of the latent binder occurs.

8. The 3D printing method as defined in claim 7 wherein the temperature ranges from about 50° C. to about 200° C.

9. The 3D printing method as defined in claim 6 wherein the activating of the latent binder evaporates fluid from the green body and coalesces polymer particles of the polymer particle dispersion.

10. The 3D printing method as defined in claim 1 wherein the pressure applied to the build material granules ranges from about 10 psi to about 10,000 psi.

11. The 3D printing method as defined in claim 1 wherein the applying of the pressure is accomplished by a pressing die positioned above the applied build material granules.

12. The 3D printing method as defined in claim 1 wherein:
the applying of the pressure occurs before the selectively applying of the fusing agent; or
the selectively applying of the fusing agent occurs before the applying of the pressure.

13. A three-dimensional (3D) printing method, comprising:
applying build material granules, each of the build material granules including a plurality of primary ceramic particles agglomerated together by a binder that is at least partially soluble in a primary solvent of a fusing agent;
applying pressure to the build material granules, thereby crushing the build material granules;
selectively applying the fusing agent on at least a portion of the build material granules or the crushed build material granules, thereby patterning the build material granules or the at least the portion of the crushed build material granules, and introducing a latent binder to the at least the portion of the build material granules or the crushed build material granules;
activating the latent binder by heating the crushed and patterned build material granules to form a cured green body layer; and
repeating the applying of the build material granules, the applying of the pressure, the selectively applying of the fusing agent, and the activating of the latent binder to form a cured green body.

14. A three-dimensional (3D) printing system, comprising:
a supply of build material granules, each of the build material granules including a plurality of primary ceramic particles agglomerated together by a binder that is at least partially soluble in a primary solvent of a fusing agent;
a build material distributor;
a pressing die;
a supply of the fusing agent, wherein the fusing agent further includes a latent binder;
an inkjet applicator for selectively dispensing the fusing agent;
a controller;
a non-transitory computer readable medium having stored thereon computer executable instructions to cause the controller to control the build material distributor, the pressing die, and the inkjet applicator to iteratively form multiple layers of build material granules which are applied by the build material distributor, pressed by the pressing die, and have received the fusing agent; and
a heater to activate the latent binder in each of the multiple layers to produce a cured green body.

15. The 3D printing system as defined in claim 14 wherein:
the primary ceramic particles are metal oxide ceramics, inorganic glasses, carbides, nitrides, borides, or a combination thereof;
the binder is a sugar, a sugar alcohol, a polymeric sugar, an oligomeric sugar, a polycarboxylic acid, polysulfonic acid, a water soluble polymer containing carboxylic or sulfonic moieties, a polyether alkoxy silane, or a combination thereof; and
the latent binder is a polymer particle dispersion.

Assignees

• Hewlett Packard Development Co

Inventors

• Monroe Michael G
• Kasperchik Vladek
• Ingle David Michael

Classifications

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B33Y50/02

  for controlling or regulating additive manufacturing processes · CPC title

• B29C64/218

  Rollers · CPC title

• B29C67/00

  Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 · CPC title

• B29C64/214

  Doctor blades · CPC title